Methods and systems for dispensing a composition

ABSTRACT

The present disclosure relates to methods and systems for filling cavities with a composition.

FIELD OF THE INVENTION

The present disclosure relates to methods and systems for dispensing a composition.

BACKGROUND OF THE INVENTION

Unit dose articles filled with compositions, particularly household care compositions such as laundry detergent, are becoming more popular with consumer. Generally, such articles are made in part by forming cavities on a web, for example a web of water-soluble film, filling the cavities with a composition, and then forming the complete unit dose article, for example by sealing and separating the articles.

Consequently, manufacturers are continually looking for ways to improve the speed and efficiency of the process of filling cavities with compositions. The webs are often disposed on a moving surface and the cavities filled as they move past a filling apparatus (e.g., a filling nozzle). A start-stop filling process, where the cavities stop under a nozzle while being filled with a composition, allows the nozzle to remain stationary but can slow down the manufacturing process.

A continuous filling process, where a nozzle moves with the cavity, can improve efficiency but also has limitations. For example, after the nozzle moves with and fills one cavity, the nozzle must return to its start position before it begins filling the next cavity. This limits the speed of the filling process and the number of cavities that can be filled in a given time period.

Filling problems are particularly acute when the web is disposed on a rotatable drum moving with continuous curvilinear motion. Cavities are typically filled at the top of the drum, when the opening of the cavity is substantially horizontal. However, if filling begins too early or continues for too long, the composition may spill out due to the tilt of the cavities. Consequently, it is often desirable to fill the cavities as quickly as possible.

The type of composition being dispensed can provide filling challenges as well. A certain minimum level of viscosity is often desirable, as low-viscosity compositions may splash out of the cavities when dispensed quickly. Compositions having higher viscosities, on the other hand, may experience problems with “stringing,” where a filament of the composition remains between the nozzle and the cavity, even when the nozzle has stopped actively dispensing the composition. As a result, the volumes able to be dispensed may be negatively impacted, as the manufacturer is often required to slow the rate of filling in order to avoid splashing and/or to stop the filling early in order to allow the stringing issues to resolve.

These problems are particularly applicable to manufacturers of unit dose detergent articles, which are often in the form of pouches that encapsulate detergent compositions (which are often viscous liquids) in water-soluble film. The pouches are typically formed by sealing together layers of film once the cavity has been filled, and splashing and/or “stringing” of the composition during a filling step may lead to poor sealing and increased risk of leakage.

Given the reasons above, there is a need to improve filling efficiencies. One way to do this is to increase the “filling window” (the space in which the cavities may be filled) without negatively impacting the speed of the line or the volumes of composition dispensed.

The present disclosure relates to methods and systems directed to increase the filling window of filling systems. As a result, the methods and systems described herein can enable a manufacturer to increase production speeds, product viscosities, and/or dispensed volumes.

SUMMARY OF THE INVENTION

In some aspects, the present disclosure relates to a method of dispensing a composition into cavities of a web that continuously moves in a machine direction, wherein the method comprises the steps of:

-   -   a) providing a web that moves continuously in a machine         direction, wherein the web comprises a plurality of cavities,         wherein the plurality of cavities comprises at least two         cavities that are aligned in the machine direction;     -   b) providing a filling apparatus, wherein the filling apparatus         comprises a plurality of nozzles, wherein the plurality of         nozzles comprises at least two nozzles that are positioned to         dispense a composition into the at least two cavities;     -   c) dispensing the composition from the at least two nozzles into         the at least two cavities while the at least two nozzles move         from a first position to a second position; and     -   d) returning the at least two nozzles to the first position.

In some aspects, the present disclosure relates to a system configured to carry out the steps of the above method.

In some aspects, the present disclosure relates to a system for dispensing a composition into cavities of a web that continuously moves in a machine direction, wherein the system comprises:

-   -   a) a continuously moveable surface configured to receive a web,         wherein the surface comprises a plurality of moulds, where the         plurality of moulds comprises at least two moulds that are         aligned in the machine direction;     -   b) a filling apparatus comprising a plurality of nozzles,         wherein at least two nozzles are positioned to dispense a         composition into at least two cavities of a web disposed on the         surface, wherein the two cavities are formed in the at least two         moulds, and wherein the at least two nozzles have a first         position and a second position;     -   wherein the at least two nozzles are configured to move from the         first position to the second position while simultaneously         dispensing the composition into the at least two cavities while         the web moves in the machine direction; and     -   wherein the at least two nozzles are configured to return to the         first position.

In some aspects, the system comprises a rotary drum, where the rotary drum comprises the moveable surface. In some aspects, the composition is a household care composition. In some aspects, the system further comprises a device positioned and configured to continuously feed a web onto the moveable surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a side view of a system described herein.

FIG. 2A shows a top view of a plurality of cavities.

FIG. 2B shows a top view of an alternate embodiment of a plurality of cavities.

FIG. 2C shows a top view of an alternate embodiment of a plurality of cavities.

FIG. 3A shows a side view of a surface with moulds disposed thereon.

FIG. 3B shows a side view of a web disposed on a surface, where the web has cavities disposed thereon.

FIG. 4A shows a filling apparatus positioned to dispense a composition into a cavity disposed on a web.

FIG. 4B shows an alternate embodiment of a filling apparatus positioned to dispense a composition into a cavity disposed on a web.

FIG. 5 shows a plurality of cavities disposed on a moveable surface.

FIG. 6 shows a side view of a rotary drum and a horizontal plane.

FIG. 7 shows a side view of a rotary drum and a filling apparatus.

FIG. 8A shows a bottom view of a filling apparatus.

FIG. 8B shows a bottom view of an alternative embodiment of a filling apparatus.

FIGS. 9A-9E show a side view of a system performing a method described herein.

FIG. 10A shows a comparison of filling windows of systems that comprise a rotary drum.

FIG. 10B shows a filling window of a system that comprises a rotary drum.

FIG. 10C shows various filling windows of a system that comprises a rotary drum.

FIG. 11 shows a side perspective view of a rotary drum and a filling apparatus.

FIG. 12A shows a filling apparatus comprising a plurality nozzles connected to a reciprocating manifold.

FIG. 12B shows a filling apparatus comprising a plurality of nozzles disposed on an endless surface.

FIG. 12C, FIG. 12D, and FIG. 12E show a filling apparatus that moves about a pivot point.

FIGS. 13A-13C show various embodiments of a plurality of nozzles connected to a supply tank.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, articles such as “a” and “an” when used in a claim, are understood to mean one or more of what is claimed or described.

As used herein, the terms “comprising,” “comprises,” “include”, “includes” and “including” are meant to be non-limiting. The term “consisting of” or “consisting essentially of” are meant to be limiting, i.e., excluding any components or ingredients that are not specifically listed except when they are present as impurities. The term “substantially free of” as used herein refers to either the complete absence of an ingredient or a minimal amount thereof merely as impurity or unintended byproduct of another ingredient. In some aspects, “substantially free” means that the composition comprises less than about 0.1%, or less than 0.01%, or even 0% of an ingredient.

As used herein, the term “solid” includes granular, powder, bar, and tablet product forms.

As used herein, the term “fluid” includes liquid, gel, paste, and gas product forms.

As used herein, the term “liquid” refers to a fluid having a viscosity of from about 1 mPa*s to about 2000 mPa*s, preferably from about 40 mPa*s to about 1000 mPa*s, more preferably from about 70 mPa*s to about 600 mPa*s at 25° C. at a shear rate of 1000 s⁻¹. In some embodiments, the viscosity of the liquid may be in the range of from about 50 mPa*s to about 200 mPa*s at 25° C. at a shear rate of 1000 s⁻¹. In some embodiments, the viscosity of the liquid may be in the range of from about 250 mPa*s to about 500 mPa*s at 25° C. at a shear rate of 1000 s⁻¹. The liquids may be Newtonian or non-Newtonian (shear thinning) liquids.

As used herein, the term “filling window” is a description of when and/or where the cavities may be suitably filled. A filling window may be determined for a single cavity, a plurality of cavities, or an entire system. Typically, the filling window is defined by two filling points: a filling start point, the point on the surface of the system at which a nozzle begins dispensing a composition into a cavity, and a filling end point, the point on the surface of the system at which the nozzle finishes dispensing the composition. The filling end point may be the point at which the nozzle finishes actively dispensing the composition (i.e., when the active flow of composition has stopped) or, particularly when the composition is a viscous composition, the point at which the nozzle finishes passively dispensing the composition (i.e., after the active flow of composition has stopped and when any residual stringing or dripping has abated).

The filling window may be described in terms of distance (“filling window distance”), where the filling window distance is a distance between the filling start point and the filling end point. The distance may be measured as a rectilinear distance or as a curvilinear distance (i.e., an arc along the surface of a rotary drum or a portion of a circumference). In some aspects, the filling window distance is from about 10 mm to about 200 mm, or from about 20 mm to about 120 mm, or from about 30 mm to about 90 mm, or from about 50 to about 80 mm, or from about 60 mm to about 70 mm. In some aspects, when the surface is part of a rotary drum, the filling window distance is from about 1% to about 10%, or from about 2% to about 6% of the circumference of the rotary drum. It is understood that the filling window distance will related to the size of the cavities being filled and to the space between the cavities.

The filling window may be described in terms of time (“filling window time”), where the filling window time is typically defined as the time spent dispensing the composition. The filling window time may also be defined as the time taken for a cavity to travel from the filling start point to the filling end point. The filling window time may also be defined as the time taken for a nozzle to move from the first position to the second position. In some aspects, the filling window time is from about 20 ms to about 1000 ms. In some aspects, the filling window time is from about 20% to about 90%, or from about 30% to about 80%, or from about 40% to about 70% of the reciprocating cycle time, where the reciprocating cycle time is the time for a number of n cavities to move by n times the distance between the centers of two consecutive cavities that are aligned in a machine direction, e.g, in a lane, where n is the number of nozzles aligned in the machine direction, e.g., in a lane of nozzles, preferably n=2.

In some aspects, the filling window time is approximately 50% or less, or approximately 40% or less, of the time required for a nozzle to move from a first position to a second position and then return to the first position.

When the filling points are disposed on a curved surface, such as on a rotary drum, the filling window may be described as an angle (“filling window angle”). In this case, the filling window may be defined as the angle subtended by the circular arc between the filling start point and the filling end point, which are typically circumferentially spaced on the surface of the drum, where the vertex of the filling window angle is located on the rotational axis of the drum. The filling window of the system is typically bisected by a vertical axis, where the vertical axis is drawn through the rotational axis of the drum and the highest point on the drum. In some aspects, the filling window angle is from about 3 to about 45 degrees, or from about 5 to about 30 degrees, or from about 10 to about 15 degrees.

As used herein, a “filling cycle” can be measured from the time a nozzle begins dispensing a composition into one cavity, finishes dispensing the composition, and begins dispensing the composition into the next cavity. Typically, this corresponds to the time required for a nozzle to start at its first position, move to its second position, and return to its first position.

As used herein, the term “simultaneously” means at least two actions are occurring at the same time, although the respective starts and stops of the actions do not necessarily occur at the same time. As used herein, the term “synchronously” means at least two actions are occurring at the same time and at the same (or substantially the same, e.g., +/−10%) rate, and, optionally, in the same direction.

All temperatures herein are in degrees Celsius (° C.) unless otherwise indicated. Unless otherwise specified, all measurements herein are conducted at 20° C. and under the atmospheric pressure.

In all embodiments of the present invention, all percentages are by weight of the total composition, unless specifically stated otherwise. All ratios are weight ratios, unless specifically stated otherwise.

Method

In some aspects, the present disclosure relates to a method of dispensing a composition into cavities of a web that continuously moves in a machine direction. In some aspects, the method comprises the steps of: (a) providing a web that moves continuously in a machine direction, wherein the web comprises a plurality of cavities, wherein the plurality of cavities comprises at least two cavities that are aligned in the machine direction; (b) providing a filling apparatus, wherein the filling apparatus comprises a plurality of nozzles, wherein the plurality of nozzles comprises at least two nozzles that are positioned to dispense a composition into the at least two cavities; (c) dispensing the composition from the at least two nozzles into the at least two cavities while the at least two nozzles move from a first position to a second position; and (d) returning the at least two nozzles to the first position.

FIG. 1 shows a side view of a filling system configured to carry out the present method. At least two cavities 110, 111 are formed on a web 100 that is moveable in a machine direction, shown by the arrow marked MD. The at least two cavities 110, 111 are aligned in the machine direction. A filling apparatus 200 is positioned above the cavities 110, 111. The filling apparatus 200 comprises at least two nozzles 210, 211 that are aligned in the machine direction, and the at least two nozzles are dispensing a composition 300 into the two cavities 110, 111 in a fill direction, shown by the arrow marked FD. The components of the system and the steps of the method are described in more detail below.

Cavities

In the methods described herein, a web is provided. Typically, the web continuously moves in a machine direction. In the present methods, the web may be continuously fed onto a moveable surface, for example from a belt, a drum, or a roll.

The web comprises a plurality of cavities disposed on the web. The cavities may be of any type suitable for receiving and holding a dispensed composition and typically have a closed bottom. In a preferred embodiment, the cavities are depressions on the web, preferably a web of film, more preferably a single web of film, which may be later sealed, preferably sealed with a second web, thereby forming a web of closed cavities. The cavities, or the web of sealed cavities may then be separated or divided, for example by cutting, to form individual articles, for example, unitized dose pouches.

The plurality of cavities comprises at least two cavities, e.g. a first cavity and a second cavity, aligned in a machine direction, forming a lane in the machine direction. Each lane may comprise from about four to about one hundred, or from about ten to about fifty, or from about twenty to about forty cavities. The plurality of cavities may be arranged into from about one to about fifty, or from about five to about thirty, or from about ten to about sixteen lanes, typically arranged side-by-side and each moving, typically synchronously, in the machine direction.

In some aspects, the plurality of cavities may form two or more compartments of a final product, such as a unit dose pouch. The compartments may be side-by-side. In some aspects, the compartments are aligned in the machine direction, so that the compartments are the at least two cavities that form a lane in the machine direction. This orientation may be particularly desirable when the two compartments are intended to contain different compositions. Thus, in some aspects, the present method relates to a process of filling at least two cavities aligned in a machine direction, where the at least two cavities are formed into at least two side-by-side compartments of a pouch, preferably, where each of the compartments is filled with a different composition. In other aspects, the two side-by-side compartments are not in the same lane; they may be in the same row, or they may be off-set from each other, in which case the two compartments would neither be in the same lane nor in the same row. The side-by-side compartments may be of different shapes and/or of different orientations. In some aspects, the side-by-side compartments form the elements of a yin-yang shape. In some aspects, the at least two cavities of the methods and systems described herein are intended to be formed into separate, distinct articles.

Typically, the plurality of cavities further comprises at least two cavities aligned in a cross-machine direction, which may form a row perpendicular to the machine direction. Each row may comprise from about one to about fifty, or from about five to about thirty, or from about ten to about sixteen cavities. The plurality of cavities may comprise from about four to about one hundred, or from about ten to about fifty, or from about twenty to about forty rows.

One of ordinary skill will understand that the number of cavities in a lane will typically correspond to the number of rows, and that the number of cavities in a row will typically correspond to the number of lanes. The size of the cavities, the spacing between the cavities, the area of the surface, and other factors will influence the number of cavities, rows, and lanes. It is understood that the cavities need not be perfectly aligned in their lanes and/or rows, but that the cavities may be somewhat offset from each other. Such an orientation may be desirable in order to save space, particularly if the shapes of the cavities allow them to be nested amongst each other.

FIGS. 2A, 2B, and 2C show non-limiting ways that a plurality of cavities 110, 111, 112 may be arranged on a surface 100.

FIG. 2A shows a top view of a plurality of cavities 110, 111, 112 disposed on a web 100 positioned on a platen (not shown). Two cavities 110, 111 are aligned in the machine direction MD and form a part of a lane of cavities 120. Two cavities 110, 112 are aligned in the cross-machine direction, indicated by the arrow marked XMD, and form a part of a row of cavities 125. The illustrated web 100 comprises four lanes 120, three rows 125, and twelve total cavities.

FIG. 2B shows a top view of a plurality of cavities in an alternate arrangement. At least two cavities 110, 111 are arranged on a web 100, forming a first lane 120. However, a cavity 112 in a second lane 121 is off-set from the first cavity 110 in the first lane 120; in the illustrated embodiment, cavity 110 and cavity 112 are in different rows.

FIG. 2C shows a top view of plurality of cavities in another alternate arrangement. At least two cavities 110, 111 are arranged on a web 100, forming a first lane 120. Another cavity 112 is next to cavity 110 in a side-by-side arrangement, forming a complementary pair of cavities, e.g., in order to form side-by-side compartments of a water-soluble pouch where each compartment is suitable for receiving different compositions, forming a first row 121. Arrows show the machine direction MD and the cross-machine direction XMD.

In some aspects, the web comprises water-soluble or water-dispersible film, which may be formed and/or sealed to partially or completely envelop the dispensed compositions. Preferably, the water-soluble or dispersible film comprises: polymers, copolymers, terpolymers, or derivatives thereof, including polyvinyl alcohols (PVA) or blends of polyvinyl alcohols, polyvinyl pyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and salts, polyaminoacids or peptides, polyamides, polyacrylamide, copolymers of maleic/acrylic acids, polysaccharides including starch and gelatine, natural gums such as xanthum and carragum, or mixtures thereof. Preferably, the film comprises polyvinyl alcohols (PVA) or blends of polyvinyl alcohols. The films may also comprise plasticizers such as glycerin, diglycerin, sorbitol, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycols up to 400 MW, neopentyl glycol, trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol, ethanolamines, and a mixture thereof. Examples of suitable films include those commercially available from MonoSol (Merrillville, Ind., USA), such as M8630 or M8900, and those described in US Patent Application 2011/0188784A1, assigned to the Procter & Gamble Company, incorporated herein by reference.

The cavities may be formed in moulds, which may be disposed on a surface, such as a platen. For example, the web, preferably comprising water-soluble film, may be fed onto surface, preferably in a continuous manner, and drawn into the moulds. The film may be drawn into the moulds by vacuum means (referred to as vacuum-forming) and/or heated before or during the forming of the pouch (referred to thermo-forming). Preferably, the cavities are formed by themoforming. The mould may be configured to mold the web into a particular shape or to provide a surface pattern to the web.

The cavity typically has a top opening, a closed bottom wall, and typically side walls between the opening and the bottom wall. The cavity is filled by dispensing a composition into the opening. When the cavity moves with curvilinear motion, preferably on a rotary drum, the closed bottom is typically radially inward to the top opening. The cavity may have a top opening defined by a top opening edge with a perimeter that forms a shape, including, for example, a square, a rectangle, a circle, an ellipse, a super-ellipse or any other shape suitable to receive a composition.

FIG. 3A shows a side view of a surface 116 with moulds 115 disposed thereon. The mould 115 has a top opening 130, a bottom wall 131, and side walls 132, 133 between the top opening 130 and the closed bottom wall 131.

FIG. 3B shows a side view of a web 100, for example a web of water-soluble film, disposed on the surface 116 and drawn into the moulds 115 to form at least two cavities 110, 111.

The perimeter of the top opening edge may define an opening plane. When a composition is dispensed into the cavity in a fill direction, an axis defined by the fill direction may form a fill angle with the opening plane; the fill angle is the right angle or the acute angle formed by the fill direction axis and the opening plane. Preferably, the fill angle is approximately 90 degrees; however, particularly when the cavity is disposed on a rotary drum, the fill angle can change as the cavity moves through the filling window. Therefore, in some aspects, when the composition is being dispensed, the fill angle may be from about 45 degrees, or from about 60 degrees, or from about 75 degrees, or from about 80 degrees, or from about 85 degrees, or from about 87.5 degrees to about 90 degrees.

FIGS. 4A and 4B both show a filling apparatus 200 comprising a nozzle 210 positioned to dispense a composition in a fill direction (shown by the arrow marked FD) into a cavity 110 disposed on a web 100. The top opening edge 134 defines an opening plane 135. The opening plane 135 and a ray in the fill direction FD form a filling angle θ_(F). In FIG. 4A, the web 100 is horizontal, and the filling angle θ_(F) is a right angle. In FIG. 4B, a substantially horizontal portion of the web 100 is shown, and the filling angle θ_(F) is an acute angle.

The web may be disposed on a surface, preferably a moving surface, more preferably an endless surface. The surface preferably moves continuously. The surface may move with horizontal rectilinear motion or with curvilinear motion, preferably curvilinear motion, in a machine direction. The surface may move at a speed of from about 0.5 meters per minute (m/min) to about 50 m/min, or from about 1 m/min to about 20 m/min, or from about 5 m/min to about 12 m/min. Regardless of whether the surface is moving with rectilinear or curvilinear motion, the rate can be determined with regard to a reference point, such as a vertical axis, by one of ordinary skill.

Where designed to operate in horizontal rectilinear motion, the horizontal portion of the endless surface can have any suitable length, typically depending on the number of process steps required to take place on this portion of the surface during the continuous horizontal motion of the surface, on the time required per step, and on the optimum speed of the surface needed for these steps. Thus, the improved filling method of the present disclosure has the advantage of enabling the surface to move more quickly or to take up less space.

FIG. 5 shows a web 100 disposed on a moveable surface 116, such as a platen, which may be moved rectilinearly by a conveyor belt continuously in the machine direction MD. The web 100 comprises at least two cavities 110, 111 formed in moulds 115 of the surface 116. A dashed vertical line marked V is shown to illustrate a representative point of reference, which can be used to help calculate the surface's speed of motion. A filling apparatus 200 comprising at least two nozzles 210, 211 is positioned above the cavities 110, 111.

Where designed to operate in curvilinear motion, the surface, typically disposed on a rotary drum, may have a substantially horizontal portion. As used herein, by a “substantially horizontal portion,” it is meant that an acute angle (θ_(H)) formed by a line tangential to a point on the substantially horizontal portion of the surface and a horizontal plane is no more than about 45 degrees, or no more than about 30 degrees, or no more than about 20 degrees, or no more than about 15 degrees, or no more than about 10 degrees, or no more than about 5 degrees. As used herein, “horizontal plane” with regard to a surface on a drum refers to a plane that is tangential to the surface of the drum, typically at the drum's highest point (compared to the drum's base that rests on the floor), where the plane is perpendicular to a vertical axis drawn through the rotational axis of a rotary drum; typically, the vertical axis will also pass through the highest point of the drum. Typically, the section of the rotary drum that is within the filling window is a substantially horizontal portion.

FIG. 6 shows a side view of a rotary drum 150 and a horizontal plane (shown as the line marked H). A vertical axis V is drawn through the rotational axis RA of the drum 150; in the illustrated embodiment, the vertical axis V intersects the drum's surface 116 of the drum 150 at the drum's highest point 160. The horizontal plane H forms a right angle with the vertical axis V. A tangential line is drawn through a point 161 on the surface 116 of the drum, where the surface 116 is considered substantially horizontal; the tangential line and the horizontal plane form an angle θ_(H). Another tangential line is drawn through a point 162 on the surface 116 of the drum, where the surface 116 is not considered substantially horizontal; the tangential line and the horizontal plane form an angle θ_(H′).

The composition is preferably dispensed when the surface is substantially horizontal, e.g., when the cavity is on a substantially horizontal portion of the surface, so that the composition does not spill out of the cavity. The time during which the curvilinearly-moving surface is substantially horizontal typically depends, for example, on the radius of the curve and on the curvilinear speed of the surface. The improved filling method of the present disclosure has the advantage, e.g., of enabling the surface to move more quickly and/or to allow for longer filling times.

Preferably, the surface is part of and/or preferably removably connected to a moving, rotating belt—for example a conveyer belt or platen conveyer belt—or a rotary drum. Then, preferably, the surface can be removed and replaced with another surface having other dimensions or comprising cavities of a different shape or dimension. This allows the equipment to be cleaned easily and/or to be used for the production of different types of products. For example, the system may comprise a belt or drum having a series of platens, where the platens then form together the forming surface or part thereof. The cavities are typically disposed on the surface of the platen. For example, each platen may comprise a plurality of moulds used to form the cavities.

Preferably, the plurality of cavities is disposed on a rotary drum. Rotary drums are described in U.S. Pat. No. 3,057,127. The composition is typically dispensed to cavities on a substantially horizontal portion of the drum, e.g., when the cavities at or near the top of the drum. The drum rotates in the machine direction, typically about a rotational axis. At least two cavities, which may be positioned on a platen, are circumferentially spaced on the drum.

FIG. 7 shows a side view of a rotary drum 150 and a filling apparatus 200. The rotary drum 150 rotates in the machine direction MD around a rotational axis RA. The rotary drum 150 has a surface 116 positioned radially outward from the rotational axis RA. A plurality of moulds 115 are disposed on the surface 116 of the rotary drum 150. A web 100 is fed from a roll 180 onto the surface 116 of the drum and drawn into the moulds 115, forming a plurality of cavities 110, 111, 112. In the non-limiting illustration shown, the cavities 110, 111, 112 are cavities that are circumferentially space and aligned to form a lane in the machine direction MD. The filling apparatus 200 comprises nozzles 210, 211 that are positioned above at least two of the cavities 110, 111, ready to dispense a composition.

Filling Apparatus

The present systems and methods further comprise a filling apparatus. The filling apparatus is configured to dispense a composition into the cavities. The filling apparatus is typically coupled to the moveable surface, for example mechanically or by software controls.

Typically, the filling apparatus comprises a plurality of nozzles. At least two nozzles are spaced from the surface and are positioned to dispense a composition into the at least two cavities aligned in a machine direction. The at least two nozzles typically have an opening that faces the surface and/or the openings of the cavities. When the at least two cavities are horizontal or substantially horizontal, typically the at least two nozzles are positioned vertically above the openings of the at least two cavities. When the cavities are on a rotary drum, the nozzles are typically positioned radially outward to the cavities.

The at least two nozzles, e.g. a first nozzle and a second nozzle, may be aligned in the machine direction, thereby forming a lane of nozzles. Each nozzle lane may comprise two or more, typically two nozzles. The plurality of nozzles may be arranged into from about one to about fifty, or from about five to about thirty, or from about ten to about sixteen nozzle lanes. Preferably, the number of nozzle lanes corresponds to the number of cavity lanes.

The plurality of nozzles may further comprise at least two nozzles positioned to dispense a composition into the at least two cavities aligned in a cross-machine direction. Typically, the at least two nozzles so positioned are aligned in the cross-machine direction, thereby forming a row of nozzles. Each row may comprise from about one to about fifty, or from about five to about thirty, or from about ten to about sixteen nozzles. The plurality of nozzles may comprise two or more, typically two rows. One of ordinary skill will understand that the number of nozzles in a row will often correspond to the number of lanes.

The at least two nozzles are typically spaced apart from each other, even more typically spaced apart by a distance approximating the distance between the center of two cavities. The distance between the at least two nozzles is typically fixed. In some aspects, the at least two nozzles, or the plurality of nozzles, have a fixed position in relation to each other. In some aspects, the at least two nozzles are connected to a manifold, which typically is moveable.

FIG. 8A shows a bottom view of a filling apparatus 200 comprising a plurality of nozzles 210, 211, 212 connected to a manifold 230. Two nozzles 210, 211 are aligned in the machine direction, indicated by the arrow marked MD, and form a lane of nozzles 220. At least two nozzles 210, 212 are aligned in the cross-machine direction, indicated by the arrow marked XMD, and form a part of a row of nozzles 225.

FIG. 8B shows a bottom view of an alternative filling apparatus 200 comprising a plurality of nozzles 210, 211, 212 connected to a manifold. Two nozzles 210, 211 are aligned in the machine direction, forming a lane 220. Additionally, rather than being aligned in a row, two nozzles 210, 212 are off-set from each other and form a pair of nozzles 215. The filling apparatus 200 comprises a plurality of nozzle pairs 215, which may be aligned in lanes and rows. The nozzles 210, 212 in a nozzle pair 215 may dispense the same composition, or they may dispense different compositions. Having each nozzle 210, 212 in a nozzle pair 215 dispense a different composition is particularly desirable when the nozzles are filling cavities that will become multiple compartments of a pouch.

The at least two nozzles, more preferably the plurality of nozzles, have a first position and a second position. The nozzles move, typically simultaneously, even more typically synchronously, from the first position to the second position, typically in the machine direction, typically moving substantially in parallel with the movement of the cavities. After the at least two nozzles move from the first position to the second position, the at least two nozzles return to the first position. The nozzles may move in rectilinear motion or in curvilinear motion, typically rectilinear motion, from the first position to the second position. It is understood that each individual nozzle has a first position and a second position, and that the first and second positions of a first nozzle does not correspond exactly to the first and second positions, respectively, of a second nozzle. However, as described above, the at least two nozzles, or the plurality of nozzles, is described as a single unit that has a first position and a second position.

The at least two nozzles dispense the composition into the at least two cavities while the nozzles move from the first position to the second position, typically while the cavities move in the machine direction. In other words, the cavities and the nozzles move simultaneously, preferably synchronously, during at least a part of the dispensing of the composition. Typically, a first nozzle dispenses a composition into a first cavity while, simultaneously or even synchronously, a second nozzle dispenses a composition into a second cavity. In some aspects, at least a third nozzles dispenses a composition into at least a third cavity.

FIGS. 9A-9E show a side view of a system performing the method described herein. In each figure, the dashed line V is shown as a point of reference. The figures show a lane of a plurality of cavities 110, 111, 113, 114, 117, 118 disposed on a web 100 that is continuously moving in a machine direction MD. The surface is horizontal or substantially horizontal, e.g., the surface has a substantially horizontal portion, and may move with rectilinear motion (e.g., on a conveyor belt) or with curvilinear motion (e.g., on a rotary drum). Positioned above the web 100 is a filling apparatus 200 comprising a plurality of nozzles 210, 211.

FIG. 9A shows the filling apparatus in a first position (FP), where the nozzles 210, 211 are positioned above the cavities 110, 111 and simultaneously dispense a composition 300 in the fill direction FD into the at least two cavities 110, 111 (i.e., a first nozzle 210 dispenses a composition 300 into a first cavity 110, and a second nozzle 211 dispenses a composition 300 into a second cavity 111).

FIG. 9B shows the nozzles 210, 211 moving synchronously with the cavities 110, 111 in the machine direction MD away from the first position (FP). As the system moves in the machine direction MD, the nozzles 210, 211 continue to dispense the composition 300 into the cavities 110, 111, which are now partially filled with the composition 300.

FIG. 9C shows the nozzles 210, 211 in a second position (SP), where the nozzles 210, 211 have stopped dispensing the composition 300 into the cavities 110, 111, which are now filled with the composition 300. Additionally, the line A-A′ shows the filling window of the illustrated system; point A is where the filling process began (i.e., where nozzle 211 began dispensing composition 300 into cavity 111), and point A′ is where the filling process ended (i.e., where nozzle 210 finished dispensing composition 300 into cavity 110).

FIG. 9D shows the surface 100 and the plurality of cavities 110, 111, 113, 114, 117, 118 continuing to move in the machine direction MD. The nozzles 210, 211, however, are returning to the first position in a reciprocating fashion, moving in a direction opposite the machine direction, indicated by the arrow marked OMD. Note that the first nozzle 210 is passing over the second cavity 111, which is already filled with the composition 300.

FIG. 9E shows the nozzles 210, 211 returned to the first position (FP). The nozzles 210, 211 are beginning to dispense the composition 300 into cavities 113, 114, beginning a new filling cycle. One of ordinary skill will understand that that the process described herein may repeat, for example, the nozzles 210, 211 may eventually fill cavities 117, 118. In effect, each nozzle in the illustrated system may fill every other cavity (e.g., nozzle 210 fills cavity 110, cavity 113, cavity 117, etc.), thereby enlarging the filling window.

Typically, the at least two nozzles dispense the composition while at least one or at least two cavities are in the filling window of the system. As described above, a benefit of the methods and systems described herein is that they tend to increase the filling window, thereby allowing the manufacturer more flexibility and efficiency in the filling process, such as increasing production speeds, product viscosity, and/or dispensed volumes.

One of ordinary skill will understand that each cavity can have a filling window. For example, a first cavity can have a first filling window, and a second cavity can have a second filling window. The first and the second filling windows may overlap, and both are comprised in the filling window of the system.

FIGS. 10A-10C show various embodiments of filling windows on a rotary drum 150.

FIG. 10A represents a relative comparison of the filling windows of a single nozzle system and of a system comprising a plurality of nozzles. A rotary drum 150 rotates about a rotational axis RA in a machine direction MD. Vertical axis V is shown as a reference. Line A-A′approximates the filling window of a system according to the present disclosure, i.e., a system that comprises a plurality of nozzles aligned in the machine direction. Line B-B′ approximates a filling window of a comparative system, i.e., a system that does not comprises a plurality of nozzles aligned in the machine direction.

FIG. 10B shows a filling window of the present system. A rotary drum 150 rotates about a rotational axis RA in a machine direction MD. Vertical axis V is shown as a reference, drawn from the rotational axis RA though the highest point (relative to the base of the drum) of the rotary drum. A filling start point 170 and a filling end point 171 are located on the surface 116 of the rotary drum 150. The distance between the filling start point 170 and the filling end point 170 is the filling window distance. The filling window distance may be measured as a rectilinear distance (i.e., a straight line), or as a curvilinear distance (i.e., along an arc tracing the circumference of the rotary drum 150); the filling window distance is less than half the circumference of the drum. Rays are drawn from the rotational axis RA through the filling start point 170 and the filling end point 171, respectively. The angle between these rays is the filling window angle θ_(A), which is less than 180°, preferably less than 135°, more preferably less than 90°, even more preferably from about 5° to about 30°.

FIG. 10C shows the filling window(s) of the present system. A rotary drum 150 rotates about a rotational axis RA in a machine direction MD. Vertical axis V is shown as a reference, drawn from the rotational axis RA though the highest point of the rotary drum. A filling start point 172 and a filling end point 171 for a first cavity 110 are shown (web not shown); the distance between them is the filling window distance for the first cavity 110. Rays are drawn from the rotational axis RA through the filling start point 172 and the filling end point 171, respectively. The angle between these rays, which is less than 180°, is the filling window angle θ_(A1) of the first cavity. Additionally, a filling start point 170 and a filling end point 173 for a second cavity 111 are shown (web not shown); the distance between the points is the filling window distance for the second cavity. Rays are drawn from the rotational axis RA through the filling start point 170 and the filling end point 173, respectively. The angle between these rays, which is less than 180°, is the filling window angle θ_(A2) of the second cavity 111. The distance between filling start point 170 and filling end point 171 is the filling window distance of the system. The angle formed by rays drawn from the rotational axis RA through the filling start point 170 and the filling end point 171, respectively, is the filling window angle θ_(A) of the system. The filling window of the system comprises the filling window of the first cavity and the filling window of the second cavity.

Typically, it is preferred that the nozzles dispense the composition when the nozzles are in an optimum dispensing position, typically when the nozzles are generally aligned with the center of the cavities. Thus, the nozzles may start moving before they begin dispensing in order to become optimally positioned. It is also understood, however, that the nozzles need not be in the optimum dispensing position in order to dispense the composition, so long as spillage of the composition is minimized or avoided entirely. Thus, the nozzles may begin dispensing before being optimally positioned, and the nozzles may end dispensing after they are no longer optimally positioned; this increases the filling window and can increase the efficiency of the system.

In some aspects, the nozzles begin dispensing the composition after the nozzles begin moving from the first position. In some aspects, the nozzles stop dispensing the composition before said at least two nozzles reach the second position.

In some aspects, the nozzles begin dispensing the composition before the nozzles begin moving from the first position. In some aspects, the nozzles stop dispensing after the nozzles reach the second position. In some aspects, the nozzles may continue dispensing the composition while the nozzles are returning to the first position, provided that the nozzles are still dispensing the composition into the cavities. The nozzles typically stop dispensing before completing their return to the first position, in order to minimize or avoid spillage.

In some aspects, the nozzles move with reciprocating motion, for example, the nozzles may move in the machine direction and in a direction opposite the machine direction. Typically, the nozzles move with approximately the same speed and in the same direction as the cavities to be filled, while dispensing a composition into the cavities. Typically, when the desired amount of composition has been dispensed by a nozzle (e.g., a cavity is partially or completely full), the nozzle stops its movement in concert with the cavity and moves in a direction opposite the machine direction until the nozzle returns to the first position (e.g., FIG. 9A, (FP)), where it is positioned above an unfilled cavity. The speed of the returning movement, for example, from the second position to the first position, may be greater than the speed of the movement during filling. The nozzle then starts moving again in the same direction as the cavities are moving, typically matching the speed of the cavities, and again dispensing the composition, as a new filling cycle begins.

The at least two nozzles may be positioned on a reciprocating system. The reciprocating system may be returnable, moving in the machine direction and in a direction opposite the machine direction, and it may be variable in speed. The reciprocating system may comprise a reciprocating arm, which may be attached to a manifold; the nozzles may be connected to the manifold or directly to the reciprocating arm. The reciprocating arm may be actuated by a linear actuator or motor. The reciprocating system may comprise fixed guides that prevent the reciprocating system from moving in non-reciprocating motion.

In some aspects, the nozzles may move with continuous motion on an endless surface, for example, a belt rotating surface. Typically, the nozzles move with the same speed as the cavities and in the same direction, such that each unfilled cavity is under the same nozzle or nozzles for the duration of the dispensing step. After dispensing stops, the nozzles rotate and return to the first position, where they may start dispensing the composition again into another unfilled cavity.

In some aspects, the nozzles may be located on a support arm that pivots on a pivot point, which is typically fixed. The nozzles can pivot about the pivot point from the first position to the second position, and then return to the first position.

In some aspects, the system performs from about 10 to about 200 filling cycles per minute. In some aspects, the system performs from about 30 to about 150, or from about 40 to about 120 filling cycles per minute. In some aspects, the system performs from about 75 to about 175, or from about 90 to about 150, or from about 100 to about 130 filling cycles per minute. The rate can be adjusted depending on the size of the cavities, the speed of the surface, and other factors.

Typically, every nozzle or a plurality of nozzles together is connected to a device that can accurately control the flow of the composition, such that only a predetermined amount of the composition is dispensed during one cycle, e.g., in one cavity. The system used in the disclosed process preferably uses a positive displacement pump and/or a pressurized vessel with a flow meter and valve to dose the correct amounts or volumes of composition per cavity; in particular, a positive displacement pump has been found to be very accurate. Hereby, the required amount or volume of product is introduced in the pump and this is then fed to the nozzles. For example, if the system is such that sixty cavities are to be filled per filling cycle, typically sixty nozzles are provided, connected to sixty positive displacement pumps (one pump per nozzle, per cavity), which are all connected to a general tank with the composition. The pumps can be adjusted depending on the composition to be dispensed. For example, if the composition is a viscous liquid, the motor driving the pumps may need to have a higher force or torque capacity. Other methods which can be used include flow measurement, for example, by use of a magnetic flow meter or mass flow meter, and pressure flow filling/measurement, which keeps the pressure constant and adjusts the time during which a valve opens and closes, thereby controlling filling time and volume dispensed.

The nozzles may dispense a particular volume in each filling cycle. In each filling cycle, each nozzle may dispense from about 0.1 mL to about 5000 mL, or from about 0.5 mL to about 1000 mL, or from about 0.5 mL to about 100 mL, or from about 0.8 mL to about 30 mL of the composition. In some aspects, in each filling cycle, each nozzle dispenses from about 0.5 mL to about 5 mL, or from about 1.0 to about 2.0 mL of the composition. In some aspects, in each filling cycle, each nozzle dispenses from about 10 to about 50 mL, or from about 12 mL to about 30 mL, or from about 15 to about 25 mL of composition. The filling window time for each filling cycle may be from about 200 ms to about 1000 ms.

Composition

The nozzles described herein dispense a composition. Typically, the at least two nozzles dispense the same composition. However, particularly where it is desired that a variety of products be produced on the same line, the at least two nozzles may dispense different compositions into different cavities. In some aspects, where at least two cavities are to be filled with different compositions, the first nozzle dispenses a first composition into the first cavity, and the second nozzle dispenses a second composition into a second cavity. In some aspects, the first nozzle and the second nozzle form a pair of nozzles, where each nozzle in the pair dispenses a different composition. In some aspects, the plurality of nozzles comprises a plurality of pairs of nozzles. In some aspects, the plurality of pairs of nozzles are aligned in the machine direction (i.e., at least four nozzles total aligned in the machine direction). In some aspects, the two cavities are two compartments of a pouch, where each compartment is filled with a different composition.

The present methods and systems provide particular benefits when dosing viscous compositions, which presents particular challenges. For example, accurate starts and stops of dosing are more difficult with high-viscosity liquids, in part due to “stringing.” Stringing occurs when filaments of composition stretch from the dosing nozzle to the cavity, or where filaments of composition hang off of the dosing nozzle, after the composition stops flowing at the end of a dosing cycle. The present methods and systems help to mitigate the stringing problem by increasing the available dosing time window, thereby allowing the stringing issues to abate while keeping constant, or even extending, the filling window. On the other hand, it is desirable for the composition to have a certain minimum level of viscosity, as low-viscosity compositions can overflow or splash out of the cavity upon filling.

Therefore, in some aspects, the composition is a viscous composition. The composition may have a viscosity of from about 1 to about 2000 centipoise, or from about 25 to about 1500 centipoise (mPa*s), or from about 50 to about 1000 centipoise. In some aspects, the composition is a laundry composition and has a viscosity of from about 200 to about 800, or from 300 to about 500 centipoise. In some aspects, the composition is an automatic dishwashing composition and has a viscosity of from about 50 to about 150, or from about 75 to about 125 centipoise. Viscosity is measured with anAR550 rheometer, available from TA Instruments, with a cone-plate geometry and a cone angle of 3° at a shear rate of 1000 sec⁻¹, measured at 25° C.

Typically, the composition has a limited amount of air entrapped (aeration). Aeration is measured as the volume of gas entrained in the liquid divided by the total volume of the composition, i.e., liquid plus gas, measured at ambient pressure and temperature conditions. Increased levels of aeration can result in, for example, imprecise dosing from one cavity to the next. Typically, the composition will have less than about 5% aeration, or less than about 3% aeration, or less than about 1.5% aeration.

Typically, the composition is a household care composition. Non-limiting examples of suitable household care compositions include cleaning compositions, fabric care compositions, and hard surface cleaners. More particularly, the compositions may be a laundry, fabric care, or dish washing composition including pre-treatment or soaking compositions and other rinse additive compositions. The composition may be a fabric detergent composition or an automatic dish washing composition. The fabric detergent composition may be used during the main wash process or could be used as pre-treatment or soaking compositions.

Fabric care compositions include fabric detergents, fabric softeners, 2-in-1 detergent and softening, pre-treatment compositions and the like. Fabric care compositions may comprise typical fabric care adjuncts, including surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfume and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids, pigments, and mixtures thereof. The composition may be a laundry detergent composition comprising an adjunct selected from the group comprising a shading dye, surfactant, polymers, perfumes, encapsulated perfume materials, structurant, and mixtures thereof.

The composition may be an automatic dish washing composition comprising an adjunct selected from surfactant, builder, sulfonated/carboxylated polymer, silicone suds suppressor, silicate, metal and/or glass care agent, enzyme, bleach, bleach activator, bleach catalyst, source of alkalinity, perfume, dye, organic or aqueous solvent, filler, and mixtures thereof.

Preferably, the composition comprises a surfactant. Surfactants can be selected from anionic, cationic, zwitterionic, non-ionic, amphoteric, or mixtures thereof. Preferably, the composition comprises anionic surfactant, non-ionic surfactant, or mixtures thereof.

The anionic surfactant may be selected from linear alkyl benzene sulfonate, alkyl ethoxylate sulphate, and combinations thereof.

Suitable anionic surfactants useful herein can comprise any of the conventional anionic surfactant types typically used in liquid detergent products. These include sulfate and sulfonate based anionic surfactants, including alkyl benzene sulfonic acids and their salts, paraffin sulfonic acids and their salts, as well as alkoxylated or non-alkoxylated alkyl sulfate materials.

Suitable nonionic surfactants for use herein include the alcohol alkoxylate nonionic surfactants. Alcohol alkoxylates are materials which correspond to the general formula: R¹(C_(m)H_(2m)O)_(n)OH wherein R¹ is a C₈-C₁₆ alkyl group, m is from 2 to 4, and n ranges from about 2 to 12. In one aspect, R¹ is an alkyl group, which may be primary or secondary, that comprises from about 9 to 15 carbon atoms, or from about 10 to 14 carbon atoms. In one aspect, the alkoxylated fatty alcohols will also be ethoxylated materials that contain from about 2 to 12 ethylene oxide moieties per molecule, or from about 3 to 10 ethylene oxide moieties per molecule. Alternative nonionic surfactants include alkyl polyglucoside nonionic surfactants.

A preferred surfactant for use in automatic dishwashing detergents is low foaming by itself or in combination with other components (e.g. suds suppressers). Preferred for use herein are low and high cloud point nonionic surfactants and mixtures thereof including nonionic alkoxylated surfactants (especially ethoxylates derived from C₆-C₁₈ primary alcohols), ethoxylated-propoxylated alcohols (e.g., Olin Corporation's POLY-TERGENT® SLF18), epoxy-capped poly(oxyalkylated) alcohols (e.g., Olin Corporation's POLY-TERGENT® SLF18B—see WO-A-94/22800), ether-capped poly(oxyalkylated) alcohol surfactants, and block polyoxyethylene-polyoxypropylene polymeric compounds such as PLURONIC®, REVERSED PLURONIC®, and TETRONIC® by the BASF-Wyandotte Corp., Wyandotte, Mich.; amphoteric surfactants such as the C₁₂-C₂₀ alkyl amine oxides (preferred amine oxides for use herein include lauryldimethyl amine oxide and hexadecyl dimethyl amine oxide), and alkyl amphocarboxylic surfactants such as MIRANOL™ C2M; and zwitterionic surfactants such as the betaines and sultaines; and mixtures thereof. Surfactants suitable for use herein are disclosed, for example, in U.S. Pat. No. 3,929,678, U.S. Pat. No. 4,259,217, EP-A-0414 549, WO-A-93/08876 and WO-A-93/08874. Surfactants comprised in an automatic dishwashing detergent may be present at a level of from about 0.2% to about 30% by weight, more preferably from about 0.5% to about 10% by weight, most preferably from about 1% to about 5% by weight of a detergent composition.

The shading dyes employed in the present laundry care compositions may comprise polymeric or non-polymeric dyes, pigments, or mixtures thereof. Preferably the shading dye comprises a polymeric dye, comprising a chromophore constituent and a polymeric constituent. The chromophore constituent is characterized in that it absorbs light in the wavelength range of blue, red, violet, purple, or combinations thereof upon exposure to light. In one aspect, the chromophore constituent exhibits an absorbance spectrum maximum from about 520 nanometers to about 640 nanometers in water and/or methanol, and in another aspect, from about 560 nanometers to about 610 nanometers in water and/or methanol. Although any suitable chromophore may be used, the dye chromophore is preferably selected from benzodifuranes, methine, triphenylmethanes, napthalimides, pyrazole, napthoquinone, anthraquinone, azo, oxazine, azine, xanthene, triphenodioxazine and phthalocyanine dye chromophores. Mono- and di-azo dye chromophores are preferred. The shading dye may comprise a dye polymer comprising a chromophore covalently bound to one or more of at least three consecutive repeat units. It should be understood that the repeat units themselves do not need to comprise a chromophore. The dye polymer may comprise at least 5, or at least 10, or even at least 20 consecutive repeat units.

The compositions can comprise one or more detergent enzymes which provide cleaning performance and/or fabric care benefits. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A typical combination is a cocktail of conventional applicable enzymes like protease, lipase, cutinase and/or cellulase in conjunction with amylase.

The compositions of the present invention may comprise one or more bleaching agents. Suitable bleaching agents other than bleaching catalysts include photobleaches, bleach activators, hydrogen peroxide, sources of hydrogen peroxide, pre-formed peracids and mixtures thereof. In general, when a bleaching agent is used, the compositions of the present invention may comprise from about 0.1% to about 50% or even from about 0.1% to about 25% bleaching agent by weight of the cleaning composition.

The compositions may comprise a brightener. Suitable brighteners are stilbenes, such as brightener 15. Other suitable brighteners are hydrophobic brighteners, and brightener 49. The brightener may be in micronized particulate form, having a weight average particle size in the range of from 3 to 30 micrometers, or from 3 micrometers to 20 micrometers, or from 3 to 10 micrometers. The brightener can be alpha or beta crystalline form.

The compositions may also optionally contain one or more copper, iron and/or manganese chelating agents. If utilized, chelating agents will generally comprise from about 0.1% by weight of the compositions herein to about 15%, or even from about 3.0% to about 15% by weight of the compositions herein. Suitable chelants include a chelant selected from the group consisting of DTPA (Diethylene triamine pentaacetic acid), HEDP (Hydroxyethane diphosphonic acid), DTPMP (Diethylene triamine penta(methylene phosphonic acid)), ethylenediaminedisuccinic acid (EDDS), 1,2-Dihydroxybenzene-3,5-disulfonic acid disodium salt hydrate, and derivatives of such chelants.

The composition may comprise a calcium carbonate crystal growth inhibitor, such as one selected from the group consisting of: 1-hydroxyethanediphosphonic acid (HEDP) and salts thereof; N,N-dicarboxymethyl-2-aminopentane-1,5-dioic acid and salts thereof; 2-phosphonobutane-1,2,4-tricarboxylic acid and salts thereof; and any combination thereof.

The compositions of the present disclosure may also include one or more dye transfer inhibiting agents. Suitable polymeric dye transfer inhibiting agents include, but are not limited to, polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof. When present in the compositions herein, the dye transfer inhibiting agents are present at levels from about 0.0001%, from about 0.01%, from about 0.05% by weight of the cleaning compositions to about 10%, about 2%, or even about 1% by weight of the cleaning compositions.

The composition may comprise one or more polymers. Suitable polymers include carboxylate polymers, polyethylene glycol polymers, polyester soil release polymers such as terephthalate polymers, amine polymers, cellulosic polymers, dye transfer inhibition polymers, dye lock polymers such as a condensation oligomer produced by condensation of imidazole and epichlorhydrin, optionally in ratio of 1:4:1, hexamethylenediamine derivative polymers, and any combination thereof.

Other suitable cellulosic polymers may have a degree of substitution (DS) of from 0.01 to 0.99 and a degree of blockiness (DB) such that either DS+DB is of at least 1.00 or DB+2DS-DS² is at least 1.20. The substituted cellulosic polymer can have a degree of substitution (DS) of at least 0.55. The substituted cellulosic polymer can have a degree of blockiness (DB) of at least 0.35. The substituted cellulosic polymer can have a DS+DB, of from 1.05 to 2.00. A suitable substituted cellulosic polymer is carboxymethylcellulose.

Another suitable cellulosic polymer is cationically modified hydroxyethyl cellulose.

Suitable perfumes include neat perfumes, perfume microcapsules, polymer assisted perfume delivery systems including Schiff base perfume/polymer complexes, starch-encapsulated perfume accords, perfume-loaded zeolites, blooming perfume accords, and any combination thereof. A suitable perfume microcapsule is melamine formaldehyde based, typically comprising perfume that is encapsulated by a shell comprising melamine formaldehyde. It may be highly suitable for such perfume microcapsules to comprise cationic and/or cationic precursor material in the shell, such as polyvinyl formamide (PVF) and/or cationically modified hydroxyethyl cellulose (catHEC).

Suitable suds suppressors include a silicone suds suppressor, an alkyl phosphate ester suds suppressor, and/or fatty acid such as stearic acid. Suds suppressor technology and other defoaming agents useful herein are documented in “Defoaming, Theory and Industrial Applications,” Ed., P. R. Garrett, Marcel Dekker, N.Y., 1973, incorporated herein by reference.

Metal care agents may be included in the composition to prevent or reduce the tarnishing, corrosion, or oxidation of metals, including aluminium, stainless steel and non-ferrous metals, such as silver and copper. Suitable examples include one or more of the following:

(a) benzatriazoles, including benzotriazole or bis-benzotriazole and substituted derivatives thereof. Benzotriazole derivatives are those compounds in which the available substitution sites on the aromatic ring are partially or completely substituted. Suitable substituents include linear or branch-chain C1-C20-alkyl groups and hydroxyl, thio, phenyl or halogen such as fluorine, chlorine, bromine and iodine.

(b) metal salts and complexes chosen from the group consisting of zinc, manganese, titanium, zirconium, hafnium, vanadium, cobalt, gallium and cerium salts and/or complexes, the metals being in one of the oxidation states II, III, IV, V or VI. In one aspect, suitable metal salts and/or metal complexes may be chosen from the group consisting of Mn(II) sulphate, Mn(II) citrate, Mn(II) stearate, Mn(II) acetylacetonate, K2TiF6, K2ZrF6, CoSO4, Co(NO3)2 and Ce(NO3)3, zinc salts, for example zinc sulphate, hydrozincite or zinc acetate.

(c) silicates, including sodium or potassium silicate, sodium disilicate, sodium metasilicate, crystalline phyllosilicate and mixtures thereof. In one embodiment, the metal care agent is a zinc salt.

If present, the composition of the invention comprises from about 0.1% to about 5%, or from about 0.2% to about 4%, or from about 0.3% to about 3% by weight of the total composition of a metal care agent.

Examples of alkalinity source include, but are not limited to, an alkali hydroxide, alkali hydride, alkali oxide, alkali sesquicarbonate, alkali carbonate, alkali borate, alkali salt of mineral acid, alkali amine, alkaloid and mixtures thereof. The composition may comprise water. However, when the composition is a liquid that will be in contact with water-soluble film, it is typically desirable to limit the amount of water so as to preserve the film's integrity and to prevent a tacky feel to the pouches. Therefore, in some aspects, the composition comprises less than about 40% water by weight of the composition, or from about 1% to about 30%, or preferably from about 2% to about 20%, or from about 5% to about 13%, water by weight of the composition.

The composition may comprise an organic solvent. The composition may comprise from about 10% to about 50%, or from about 15% to about 40%, by weight of the liquid composition, of the organic solvent. Suitable organic solvents include low molecular weight alcohols and/or low molecular weight glycols, wherein “low molecular weight” in this context means a molecular weight less than about 500 Daltons. Suitable organic solvents preferably include glycerol, 1,2-propanediol, 1,3-propanediol, dipropylene glycol, diethylene glycol, sorbitol, and mixtures thereof.

Pouch Formation

Preferably, the cavities described herein will be formed into pouches, which may be unit dose articles. In some aspects, the present disclosure further relates to methods of forming pouches, wherein the pouches are formed, in part, by filling the cavities according to the steps described herein. A more detailed description of pouch formation is given below.

The processes, or independent parts of the process, of the present disclosure may be continuous or intermittent, preferably continuous. The process comprises the general steps of forming a cavity, preferably by forming a web comprising a water-soluble film into a mould to form said cavity, filling the cavity with a composition according the steps described herein, preferably a liquid composition, and closing the cavity filled with a composition, preferably with a second water-soluble film, to form a pouch, such as a unit dose article. Preferably, the process is one in which a web of unit dose article are made, said web is then cut to form individual unit dose articles. Typically, the cavities correspond to unit dose articles that will be formed. A unit dose article may be formed from one cavity or from a plurality of cavities.

In some aspects, the first web, e.g., film, may be formed into cavities that will form more than one compartment of a pouch. In some aspects, the compartments formed from the cavities are in a side-by-side or a ‘tire and rim’ orientation. The second film may also comprise compartments, which may or may not comprise compositions. Alternatively, the second film may be a second closed pouch used to close the cavities that will form the multicompartment pouch.

The unit dose article may be made by thermoforming, vacuum-forming, or a combination thereof. Unit dose articles may be sealed using any sealing method known in the art. Suitable sealing methods may include heat sealing, solvent sealing, pressure sealing, ultrasonic sealing, pressure sealing, laser sealing or a combination thereof. Examples of continuous in-line processes of manufacturing water-soluble cavities are set forth in U.S. Pat. No. 7,125,828, U.S. 2009/0199877A1, EP 2380965, EP 2380966, U.S. Pat. No. 7,127,874 and US2007/0241022 (all to The Procter & Gamble Company, Ohio, USA). Examples of non-continuous in-line processes of manufacturing water-soluble cavities are set forth in U.S. Pat. No. 7,797,912 (to Reckitt Benckiser, Berkshire, GB).

The unit dose articles may be dusted with a dusting agent. Dusting agents can include talc, silica, zeolite, carbonate or mixtures thereof.

An exemplary means of making the unit dose article of the present disclosure is a continuous process for making an article, comprising the steps of:

a. continuously feeding a first web, such as a first water-soluble film, onto a horizontal portion of an continuously and rotatably moving endless surface, which comprises a plurality of moulds, or onto a non-horizontal portion thereof and continuously moving the film to said horizontal portion; b. forming from the film on the horizontal portion of the continuously moving surface, and in the moulds on the surface, a continuously moving, horizontally positioned web of open cavities; c. filling the continuously moving, horizontally positioned web of open cavities with a composition, to obtain a horizontally positioned web of open, filled cavities; d. closing the web of open, filled cavities, preferably continuously, to obtain closed pouches, preferably by feeding a second web, such as a second water-soluble film, onto the horizontally positioned web of open, filled cavities, to obtain closed pouches; and e. optionally sealing the closed pouches to obtain a web of closed pouches.

The second web, such as a second water-soluble film, may comprise at least one open or closed compartment.

In one embodiment, a first web of open cavities is combined with a second web of closed pouches preferably wherein the first and second webs are brought together and sealed together via a suitable means, and preferably wherein the second web is on a rotating drum set-up. In such a set-up, pouches are filled at the top of the drum and preferably sealed afterwards with a layer of film, the closed pouches come down to meet the first web comprising cavities, preferably open cavities, formed preferably on a horizontal forming surface. It has been found especially suitable to place the rotating drum unit above the horizontal forming surface unit. The cavities of the first web and/or the second web may be filled according to the steps described herein.

Preferably, the resultant web of closed pouches is cut to produce individual unit dose articles.

The pouches may be printed thereon by any suitable method. Typically, a printable material (e.g., ink) is applied to the water soluble film. The printing may be performed before or after the film is formed into a pouch.

System

The present disclosure further relates to a system configured to carry out the steps of the method described herein. The system typically is configured to dispense a composition into a plurality of cavities on a continuously moving web.

More specifically, the present disclosure relates to a system for dispensing a composition into cavities of a web that continuously moves in a machine direction, where the system comprises: a) a continuously moveable surface configured to receive a web, where the surface comprises a plurality of moulds, where the plurality of moulds comprises at least two moulds that are aligned in the machine direction; b) a filling apparatus comprising a plurality of nozzles, where at least two nozzles are positioned to dispense a composition into at least two cavities of a web disposed on the surface, where said two cavities are formed in the at least two moulds, and where the at least two nozzles have a first position and a second position; where the at least two nozzles are configured to move from the first position to the second position while dispensing, preferably simultaneously, the composition into the at least two cavities while the web moves in the machine direction; and where the at least two nozzles are configured to return to the first position.

In some aspects, the system comprises a rotary drum, where the rotary drum comprises the moveable surface. In some aspects, the composition is a household care composition. In some aspects, the system further comprises a device positioned and configured to continuously feed said web onto said moveable surface. The system is described in more detail below and may further include any of the components described in the above method disclosure.

The system comprises a continuously moveable surface configured to receive a web. The surface typically comprises a plurality of moulds, where the plurality of moulds comprises at least two moulds that are aligned in the machine direction, typically forming a lane. The system typically comprises a rotary drum, where the rotary drum comprises the moveable surface. In such cases, the at least two moulds are preferably circumferentially spaced to form a lane in the machine direction. The plurality of moulds typically comprises at least two moulds aligned in a cross-machine direction to form a row. Preferably, the moulds are configured to form a cavity from a web, typically water soluble film, which may be filled and formed into a unit dose article.

In a preferred embodiment, the system comprises a rotary drum that rotates in a machine direction around an axis of rotation. The rotary drum comprises a surface positioned radially outward from the axis of rotation. Typically, the surface extends axially, forming a substantially cylindrical surface. The rotary drum is typically connected to an actuator that is configured to cause the drum to rotate. A plurality of moulds is disposed on the surface, where the moulds have a closed bottom that is radially inward relative to a top opening, preferably with side walls between, where the side walls are between (and preferably connect) the closed bottom and the top opening.

The system may further comprise a filling apparatus, typically spaced away from the surface. When the surface is on a rotary drum, the filling apparatus is typically positioned radially outward relative to the surface of the drum. The filling apparatus is typically coupled, for example, mechanically or by software controls, to the surface, e.g., the surface of a rotary drum. The filling apparatus comprises a plurality of nozzles. The plurality of nozzles comprises at least two nozzles, where the at least two nozzles are positioned to dispense a composition, typically simultaneously, into at least two cavities of a web disposed on the surface, where the two cavities are formed in the at least two moulds (e.g., a first nozzle dispenses a composition into a first cavity, and a second nozzle dispenses the same or a different composition into a second cavity). The nozzles have a first position, typically where the nozzles begin dispensing a composition, and a second position, typically where the nozzles stop dispensing a composition. Suitable compositions are described above.

FIG. 11 shows a side perspective view of a rotary drum 150 that rotates around a rotational axis RA in a machine direction MD. The rotary drum 150 comprises a radially positioned, continuously moveable surface 116 configured to receive a web, where the surface 116 comprises a plurality of moulds 115, 115′, 115″, where at least two moulds 115, 115′ are circumferentially spaced and aligned in the machine direction MD, forming a lane 120. At least two moulds 115′, 115″ are aligned in a cross-machine direction XMD, forming a row 125. FIG. 11 further shows a filling apparatus 200, spaced apart and radially outward from the surface 116 of the rotary drum 150. The filling apparatus 200 comprises a plurality of nozzles 210, 211, 212 positioned to dispense a composition into cavities on a web, where the cavities are formed by being drawn in to the moulds 115, 115′, 115″, where at least two nozzles 210, 211 are aligned in the machine direction MD, where the machine direction is relative to the moulds 115′, 115″ at a horizontal portion of the surface 100, forming a lane of nozzles 220, and at least two nozzles 210, 212 are aligned in the cross-machine direction XMD, forming a row of nozzles 225. The plurality of nozzles are connected to a manifold 230, which is connected to a reciprocating arm 235, capable of moving the filling apparatus 200 in the machine direction MD (outward direction) and a direction opposite the machine direction OMD (inward direction).

Typically, the at least two nozzles are aligned in the machine direction, thereby forming a lane of nozzles. Each lane may comprise two or more, typically two, nozzles. The plurality of nozzles may be arranged into about one to about fifty, or about five to about thirty, or about ten to about sixteen lanes. Preferably, the number of nozzle lanes corresponds to the number of cavity lanes.

The plurality of nozzles may further comprise at least two nozzles positioned to dispense a composition into the at least two cavities aligned in a cross-machine direction. Typically, these nozzles are aligned in the cross-machine direction, thereby forming a row of nozzles. Each row may comprise from about one to about fifty, or from about five to about thirty, or from about ten to about sixteen nozzles. The plurality of nozzles may comprise two or more, typically two, rows. One of ordinary skill will understand that the number of nozzles in a row will often correspond to the number of lanes.

As described above, the nozzles are configured to move from the first position to the second position while dispensing, preferably simultaneously, the composition into the at least two cavities while the web moves in the machine direction. The nozzles are further configured to return to the first position.

The at least two nozzles may be positioned on a reciprocating system. The reciprocating system may be returnable, moving in the machine direction and opposite the machine direction, and it may be variable in speed. The reciprocating system may comprise a reciprocating arm, which may be attached to a manifold, where the nozzles are fixed thereto. The reciprocating arm may be actuated by a linear actuator or motor. The reciprocating system may comprise fixed guides that prevent the reciprocating system from moving in non-reciprocating motion. The guides of the reciprocating system may guide the reciprocating arm in a linear motion or in a curved trajectory.

FIGS. 12A-12E show a variety of filling apparatuses (200).

FIG. 12A shows a filling apparatus 200 comprising at least two nozzles 210, 211 connected to a manifold 230, which is connected to a reciprocating arm 235, which is connected to a linear actuator 240.

FIG. 12B shows a filling apparatus 200 comprising at least two nozzles 210, 211 disposed on an endless surface in the form of a conveyor belt that continuously moves on at least two rotational axes 255, 255′. A first nozzle 210 has moved in the machine direction MD from a first position (FP) to a second position (SP). A second nozzle is currently at a first position (FP). A third nozzle 212 is in the process of returning to the first position (FP).

FIGS. 12C-12E show a filling apparatus 200 comprising a plurality of nozzles 210, 211 connected to a support arm 260 that is capable of moving about a pivot point 265. FIG. 12C shows the filling apparatus 200 at a resting position. FIG. 12D shows the filling apparatus 200 having pivoted about the pivot point 265 to arrive at a first position (FP). FIG. 12E shows the filling apparatus 200 having pivoted about the pivot point 265 in the machine direction MD to arrive at a second position (SP). The filling apparatus 200 can then pivot in the direction opposite the machine direction OMD to return to the first position. In effect, the filling apparatus 200 swings from the first position FP to the second position SP and back to the first position FP.

FIGS. 13A-13C show schematic views of a variety of filling apparatuses 200.

FIG. 13A shows a plurality of nozzles 210, 211 connected to a supply tank 270, which contains a composition 300 by a plurality of supply lines 275, 276.

FIG. 13B shows a plurality of nozzles 210, 211 connected to a single supply line 275, which is connected to a supply tank 270, which contains a composition 300. The supply line 275 is connected to the tank 270 at a single point, but the supply line 275 divides to connect to the nozzles 210, 211.

FIG. 13C shows a plurality of nozzles 210, 211 connected to a support piece 280, which is connected to a supply line 275, which connects to a supply tank 270, which contains a composition 300. The support piece 280 is configured to divide the supply of composition among the plurality of nozzles 210, 211.

In some aspects, the system further comprises a device positioned and configured to continuously feed the web onto the moveable surface. The device may be a belt, a drum, or a roll.

Process for Washing

The articles formed by the methods and systems described herein may be used, for example, in conventional hand or machine washing processes, particularly in machine washing of laundry or dishware. The article is typically placed in the washing machine along with the laundry or dishware to be washed, and the washing or cleaning operation is carried out. The articles may be used in combination with other compositions, such as fabric additives, fabric softeners, rinse aids, and the like.

Examples

Table 1 is a non-limiting illustration of compositions suitable for dosing according to the methods and systems described herein. The compositions are dosed into cavities comprised on webs made of water-soluble film according to those disclosed in US Patent Application 2011/0188784A1, and webs comprising M8630 water-soluble film, available from MonoSol LLC (Merrillville, Ind., USA).

TABLE 1 Composition: 1 2 3 4 Dosage (mL) 24 34 5 1.5 Ingredient (wt %) Linear C₉-C₁₅ 20 20.0 20 Alkylbenzene sulfonic acid C₁₂₋₁₄ alkyl 9-ethoxylate 15 17.0 17 Citric Acid 1 Fatty acid 8 13.0 18 C12-14 alkyl ethoxy 3 9 sulfate Chelant 1 0.6 1 (DTPA) (HEDP) (EDDS) Ethoxysulfated 2 2.2 Hexamethylene Diamine Dimethyl Quat Polymer Alkoxylated polyamine¹ 5 5.0 4 Enzymes 1 0-3 Structurant 0.15 Brightener 0.2 Hueing dye² 0.035 0.12 Glycerol 6 5 15 1,2 propanediol 11 5 30 84 Water 10 10 4 Mono-ethanolamine or To pH To pH 8.0 To pH 8.0 To pH 8.0 NaOH (or mixture about 7.4 thereof) Additives, Minors To 100% ¹Polyethylenimine (MW = 600) with 20 ethoxylate groups per —NH ²Ethoxylated thiophene, EO (R₁ + R₂) = 5

Table 2 shows compositions suitable for use in an automatic dishwasher (amounts given in grams). The compositions are introduced into cavities that will form dual-compartment water-soluble unitized dose article having a first compartment comprising a solid composition (in powder form) and a second compartment comprising the liquid composition. The compositions may be dosed according to the methods and systems disclosed herein. The water-soluble film used can be M8630 film as supplied by Monosol.

TABLE 2 A B Powder Percarbonate 1.41 1.41 TAED 0.32 0.32 Cobalt catalyst 0.0013 — Mn TACN — 0.0013 Sodium 7.17 7.17 carbonate Sodium 2.5 2.5 Sulphate Amylase 0.0013 0.0013 Protease 0.013 0.013 Acusol 588 1.20 1.20 NI surfactant 0.10 0.10 BTA 0.0080 0.0080 HEDP 0.10 0.10 MGDA 2.20 2.20 Liquid NI surfactant 1.17 1.17 DPG 0.44 0.44 Amine Oxide 0.05 0.05 Glycerine 0.08 0.08 PEI600 EO7 0.25 0.25 PO1 90% Quat

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

What is claimed is:
 1. A method of dispensing a composition into cavities of a web that continuously moves in a machine direction, wherein said method comprises the steps of: a) providing a web, typically disposed on a moveable surface, that moves continuously in a machine direction, wherein said web comprises a plurality of cavities disposed on said web, wherein said plurality of cavities comprises at least two cavities that are aligned in said machine direction; b) providing a filling apparatus, wherein said filling apparatus comprises a plurality of nozzles, wherein said plurality of nozzles comprises at least two nozzles that are positioned to dispense a composition into said at least two cavities; c) dispensing said composition from said at least two nozzles into said at least two cavities while said at least two nozzles move from a first position to a second position; and d) returning said at least two nozzles to said first position.
 2. A method according to claim 1, wherein said web comprises water-soluble film.
 3. A method according to claim 2, wherein said cavities are formed in moulds.
 4. A method according to claim 3, wherein said moulds are disposed on a platen.
 5. A method according to claim 1, wherein said cavities are formed by thermoforming.
 6. A method according to claim 1, wherein said web is disposed on an endless surface.
 7. A method according to claim 1, wherein said web is disposed on a rotary drum.
 8. A method according to claim 7, wherein said at least two cavities are spaced circumferentially on said drum.
 9. A method according to claim 1, wherein said plurality of cavities further comprises at least two cavities aligned in a cross-machine direction, and wherein said plurality of nozzles further comprises at least two nozzles positioned to dispense a composition into said at least two cavities aligned in a cross-machine direction.
 10. A method according to claim 1, wherein said at least two nozzles are aligned in said machine direction.
 11. A method according to claim 1, wherein said at least two nozzles move from said first position in said machine direction to said second position.
 12. A method according to claim 1, wherein said plurality of nozzles move in rectilinear motion from said first position to said second position.
 13. A method according to claim 1, wherein said plurality of nozzles are positioned on a reciprocating arm.
 14. A method according to claim 1, wherein said at least two nozzles begin dispensing said composition after said at least two nozzles begin moving from said first position.
 15. A method according to claim 1, wherein said composition is a household care composition.
 16. A method according to claim 1, wherein said composition is a liquid having a viscosity of from about 1 mPa*s to about 2000 mPa*s at 25° C. and at a shear rate of 1000 s⁻¹.
 17. A method according to claim 1, wherein said at least two cavities aligned in said machine direction are formed into at least two side-by-side compartments of a pouch.
 18. A method according to claim 17, wherein each of said cavities is filled with a different composition.
 19. A method according claim 1, further comprising the step of sealing the cavities, thereby forming a web of closed cavities.
 20. A method according to claim 1, further comprising the step of separating the cavities, thereby forming individual articles.
 21. A system for dispensing a composition into cavities of a web that continuously moves in a machine direction, wherein said system comprises: a) a continuously moveable surface configured to receive a web, wherein said surface comprises a plurality of moulds, where said plurality of moulds comprises at least two moulds that are aligned in said machine direction; b) a filling apparatus comprising a plurality of nozzles, wherein at least two nozzles are positioned to dispense a composition into at least two cavities of a web disposed on said surface, wherein said two cavities are formed in said at least two moulds, and wherein said at least two nozzles have a first position and a second position; wherein said at least two nozzles are configured to move from said first position to said second position while simultaneously dispensing said composition into said at least two cavities while said web moves in said machine direction; and wherein said at least two nozzles are configured to return to said first position.
 22. A system according to claim 21, wherein said system comprises a rotary drum, wherein said rotary drum comprises said moveable surface.
 23. A system according to claim 21, wherein said composition is a household care composition.
 24. A system according to claim 21, wherein said system further comprises a device positioned and configured to continuously feed said web onto said moveable surface. 